Method for manufacturing a piston valve for valved wind musical instruments

ABSTRACT

A method for manufacturing a piston valve comprising boring a plurality of pairs of holes in the predetermined portions of the peripheral surface of the hollow sliding member of the piston valve, said member being made of wear resistant material such as monel metal, inserting a flexible rod or tube through each pair of the holes, filling the hollow sliding member with moldable material with the rod kept in a predetermined curved state to permit the material to be cured, and thereafter withdrawing the rod from the member.

United States Patent 1 3,694,884 Kondo [451 Oct. 3, 1972 METHOD FOR MANUFACTURING A [56] References Cited PISTON VALVE FOR VALVED WIND UNITED TATE PATENT MUSICAL INSTRUMENTS 3 581 364 6/1971 S W S S 29/157 1 R yse [72] Hamamatsu Japan 240,459 4/1881 Quinby ..264/3l3 x [73] Assignee: Nippon Gakki Seizo Kabushiki 1,553,154 9/ 1925 Gammeter ..264/313 X Kaisha, l-lamamatsu-shi, Japan P E J h F C be nmary xarruner o n amp [22] Ffled: June 1970 Assistant Examiner-Donald C. Reiley, Ill [211 App] 47 013 Attorney-Irving M. Weiner [57] ABSTRACT [30] Foreign Application Priority Data A method for manufacturing a piston valve comprising June 20, Japan boring a plurality of pairs of holes in-the predetermined portions of the peripheral surface of the hollow 9/ -1 29/527.l, 29/DIG- 29, sliding member of the piston valve, said member being 264/267, 264/313 made of wear resistant material such as monel metal, [51] Int. Cl. ..B21k 29/00 inserting a flexible rod or tube through each pair of [58] Field of Search ..29/ 157.1 R, 527.1, DIG. 29; the holes, filling the hollow sliding member with moldable material with the rod kept in a predetermined curved state to permit the material to be cured, and thereafter withdrawing the rod from the member.

4 Claims, 7 Drawing Figures PATENTEBBM m2 3,694,884

F/ 6 IINVENTOR. Neil w: Olson His Attorney METHOD FOR MANUFACTURING A PISTON VALVE FOR VALVED WIND MUSICAL INSTRUMENTS BACKGROUND OF THE INVENTION This invention relates to valved wind musical instruments in general and, particularly, to a piston valve for valved brass wind musical instruments such as comets and trumpets and an improved method for manufacturing the same.

In the past, a piston valve for valved wind instru ments was manufactured by first boring a plurality of pairs of holes in the prescribed portions of the peripheral surface of a hollow cylindrical member made of wear resistant material such as monel metal; inserting into the holes of the member soft thin-walled tubes made of, for example, brass to fonn the conventional ways or passages for the passage of the sound, each tube being prepared in advance by rendering it considerably soft by means of annealing, bending it into a prescribed-curvature and subjecting it to required deformation to facilitate its subsequent insertion into the hole of the cylindrical member; soldering the tube to the hollow cylindrical member after releasing it from saiddeformation; and cutting off the unnecessary end portion of the tube projecting outwardly through the hole of the member.

However, the conventional method has several drawbacks, namely; the bending of tubes for insertion through the sliding hollow member tended to cause them to display creases which varied in size with the manufacturing process to which they were subjected, for example, annealing; there were also considerable difficulties in soldering the tube to the hollow member due to their different materials; and the bit cutting of the unnecessary end portion of the tube was likely to cause it to peel off in flakes or be crushed, rendering said cutting operation difficult.

Generally speaking, the conventional method was handicapped by not only low yield but also high production cost.

SUMMARY OF THE INVENTION The primary object of the present invention is to eliminate the aforementioned shortcomings of the prior method so as to prominently facilitate it, thereby providing a method for manufacturing a piston valve for cornets, trumpets and like instruments, and products obtained thereby, which is extremely adapted for mass production. The piston valve manufactured by the present invention reduces deviation in the curvature of the way or bore for the passage of the sound in a piston valve and provides complete airtightness for said way or bore and improves tone quality due to the smooth formation of the inner wall surface of said way or bore.

BRIEF EXPLANATION OF THE DRAWING FIG. 1 is a longitudinal sectional view of the valve assembly of a valved wind instrument embodying the present invention;

FIGS. 2A to 2D are fragmentary views, respectively, showing the sequential steps of manufacturing a piston valve according to the present invention;

FIG. 3 illustrates a spacer employed in the manufacture of the piston valve; and

FIG. 4 is a longitudinal sectional view of a piston valve according to another embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to FIG. 1, there is shown a valve assembly for a valved wind musical instrument embodying the present invention. A valve casing or cylinder 10 contains therein a piston valve 11 so as to enable the reciprocatory movement of the latter. The valve 11 carries at its upper end a tubular barrel 12 having oppositely disposed longitudinal slots 13 and a bottom plate 14. The barrel 12 is connected at its upper end to a stem 15 with a finger key 16. A coiled spring 17 abuts at its lower end with an abutment 18 which, in turn, is slidably secured to the cylinder 10 so as to bring the spring acted piston valve i 1 back to its original position when the finger key 16 associated therewith is depressed.

The manufacture of the piston valve will be now described by reference to FIG. 2. Firstly, plural, say, two pairs of holes 21 are bored in a thin-walled, hollow sliding member or pipe 20 made of wear resistant material such as monel metal (FIG. 2A). The pipe preferably has a rough inner surface formed, if necessary, using tools such as files. Then, to one end of the pipe there is secured a barrel 12 with a bottom plate 14 (FIG. 2B), followed by inserting rods through the pairs of holes 21. The rods are preferably tubular rods 22 made of flexible material such as silicone rubber, with the peripheral surface of the rod 22 being coated with a parting or releasing agent. The portion of the rod present in the pipe 20 is kept in a predetermined curvature by a suitable jig (FIG. 2C). Then, moldable material or preferably thermosetting resins such as epoxy, polyester, phenol or melamine resins in a fluidized state is filled into the pipe carrying the rod 22 to be cured. To avoid the deformation of the flexible rod 22 when the moldable material is filled into the pipe 20, the rod 22 may be formed into a tubular shape and suitable fillers may be inserted therein or alternatively air pressure or oil pressure may be applied therein. After the air pressure or the fillers, if used, is removed from the tubular rod, the rod is withdrawn from the pipe, and bores or ways for the passage of the sound have been formed in the moldings 26 within the pipe (FIG. 2D), thus completing the manufacture of the piston valve. When the rods are set in the pipe close to each other, there may be disposed therebetween a suitable insert or spacer 23 such as glass fiber mats, paper, etc., as illustrated in FIG. 3, so as to facilitate the penetration of the moldable material into the pipe.

As shown in FIG. 4, it is preferred that there be provided a throughbore 25 lengthwise of the piston valve and connecting both ends of the piston valve, which throughbore 25 will permit air within both ends of the valve casing to pass freely therethrough. It will be apparent that such bore may be perforated, together with the formation of the aforesaid passageways for the passage of the sound, in substantially the same manner as in the latter.

According to the present invention, the bores or ways for the passage of the sound are formed in the pipe through much simplified manufacturing process, with the easier formation of predetermined curvature of said bores and the smooth formation of the inner wall surface thereof, with the result that the tonal quality obtained becomes much more improved than conventional piston valves.

Although several forms of the present invention have been disclosed, it should be apparent to those skilled in the art of manufacturing piston valves for valved wind musical instruments that other forms may be had, all coming within the spirit of the invention and the scope of the appended claims.

What is claimed is:

1. A method for manufacturing a piston valve for valved wind musical instruments comprising the steps of boring a plurality of pairs of holes in predetermined portions of the peripheral wall of a hollow sliding member made of a wear resistant material; inserting flexible rods of rubber through each pair of holes in such a manner that the portion of each of the rods present in the member is kept in a predetermined curvature; filling moldable material into the hollow interior of the sliding member carrying the rods and encompassing the same before said material is cured; curing the moldable material; and withdrawing the rods from the cured moldable material and the sliding member through one of each pair of holes to form air passages between each pair of holes.

2. The method according to claim 1, further comprising the step of interposing spacers between the adjacent rods within the sliding member so as to leave spaces therebetween, permitting easy penetration of the moldable material through the interspace between the rods.

3. A method for manufacturing a piston valve for valved wind musical instruments comprising the steps of boring a plurality of pairs of holes in predetermined portions of the peripheral wall of a hollow sliding member made of a wear resistant material;

inserting flexible rods formed into a tubular shape through each pair of the holes in such a manner that the portion of each of the rods present in the member is kept in a predetermined curvature; filling the hollow flexible rods with fluids;

filling moldable material into the hollow interior of the sliding member carrying the rods and encompassing the same before said material is cured;

said fluid within said hollow flexible rods preventing the deformation of said rods when the moldable material is filled into the sliding member;

curing the moldable material; and

withdrawing the flexible rods from the cured moldable material and the sliding member through one of each pair of holes to form air passages between each pair of holes.

4. The method according to claim 3, further comprising the step of interposing spacers between the adjacent rods within the sliding member so as to leave spaces therebetween, permitting easy penetration of the moldable material through the interspace between the rods.

T TED STATES TATENT @TTTCT Patent No. 3,694,884 Dated October 3, 1972 Inventor s) MASARU KONDO It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Cancel the illustrative drawing appearing on the cover page and the sheet of drawing and substitute the attached sheet of drawing.

Signed and sealed this 20th day of November 1973.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. RENE D. TEGTMEYER Attesting Officer Acting Commissioner of Patents 'ORM PO-IOSO (10-69) USCQMM-DC 60376-F'59 fl' U,S. GOVERNMENT PRINTING OFFICE: I969 0-366-334.

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PATENT N0.a 3,694,884

INVENTOR.

0 NM w Val/h? 

1. A method for manufacturing a piston valve for valved wind musical instruments comprising the stEps of boring a plurality of pairs of holes in predetermined portions of the peripheral wall of a hollow sliding member made of a wear resistant material; inserting flexible rods of rubber through each pair of holes in such a manner that the portion of each of the rods present in the member is kept in a predetermined curvature; filling moldable material into the hollow interior of the sliding member carrying the rods and encompassing the same before said material is cured; curing the moldable material; and withdrawing the rods from the cured moldable material and the sliding member through one of each pair of holes to form air passages between each pair of holes.
 2. The method according to claim 1, further comprising the step of interposing spacers between the adjacent rods within the sliding member so as to leave spaces therebetween, permitting easy penetration of the moldable material through the interspace between the rods.
 3. A method for manufacturing a piston valve for valved wind musical instruments comprising the steps of boring a plurality of pairs of holes in predetermined portions of the peripheral wall of a hollow sliding member made of a wear resistant material; inserting flexible rods formed into a tubular shape through each pair of the holes in such a manner that the portion of each of the rods present in the member is kept in a predetermined curvature; filling the hollow flexible rods with fluids; filling moldable material into the hollow interior of the sliding member carrying the rods and encompassing the same before said material is cured; said fluid within said hollow flexible rods preventing the deformation of said rods when the moldable material is filled into the sliding member; curing the moldable material; and withdrawing the flexible rods from the cured moldable material and the sliding member through one of each pair of holes to form air passages between each pair of holes.
 4. The method according to claim 3, further comprising the step of interposing spacers between the adjacent rods within the sliding member so as to leave spaces therebetween, permitting easy penetration of the moldable material through the interspace between the rods. 